Apparatus for separating label assembly

ABSTRACT

A label assembly including a face sheet, a back sheet, and a layer of an adhesive positioned between the face sheet and the back sheet. A separation line divides the label assembly into at least two portions. The separation line is formed by a first tearable line of separation extending across the back sheet and a second tearable line of separation extending across the face sheet. The first tearable line of separation is offset with respect to the second tearable line of separation, and at least one of the first and second tearable lines of separation includes a non-linear portion directed toward and/or an angled portion extending at an angle to an other of the at least one of the first and second tearable lines of separation.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to a label assembly and, moreparticularly, to a sheet of self-adhesive labels that are more easilyremoved from a backing and/or a surrounding matrix, and a correspondingmethod.

2. Discussion of Related Art

Self-adhesive labels on printable sheets for printing, such as through amechanical printer, an electromechanical printer, a printing press, adigital printing or imaging device, having individual address labels areknown. After printing, each label is removed from the sheet and appliedto the desired substrate, such as an envelope for mailing. Removal ofthe labels by hand is generally performed by bending back the labelsheet in a vicinity of a corner of the first label to be removed, whichcauses separation of the label and the liner. U.S. Patent ApplicationPublication 2005/0089663 describes an attempt to make the removal ofthese labels easier or more efficient for the user. There remains a needfor further improvements for label sheets to promote efficient labelremoval, particularly for relatively large mailings or projects.

SUMMARY OF THE INVENTION

A general object of the invention is to provide an improved labelassembly having a removable portion for exposing an end portion of thelabels thereon.

A more specific objective of the invention is to overcome one or more ofthe problems described above.

The general object of the invention can be attained, at least in part,through a label assembly including a face sheet, a back sheet, and alayer of an adhesive positioned between the face sheet and the backsheet. A separation line divides the label assembly into at least twoportions. The separation line is formed by a first tearable line ofseparation extending across the back sheet and a second tearable line ofseparation extending across the face sheet. The first tearable line ofseparation can be offset with respect to the second tearable line ofseparation, and the separation line includes, at an end, a non-linearportion and/or an angled portion of one of the first and second tearablelines of separation extending at an angle to an other of the at leastone of the first and second tearable lines of separation.

The invention further comprehends a label assembly including a backsheet and a face sheet releasably adhered to the back sheet. The facesheet includes a label column of a plurality of labels and a matrixbordering the label column. Each label can abut a portion of the matrixand can be separated from the portion of the matrix, for example by atleast one die cut. A first tearable line of separation is formed in theback sheet and runs below the labels within the label column. A secondtearable line of separation is formed in the matrix, and the first andsecond tearable lines of separation are offset from each other. In someembodiments of the invention, at least one of the first and secondtearable lines of separation is or includes an angled portion extendingat an angle to an other of the first and second tearable lines ofseparation. In other embodiments of the invention, the first tearableline of separation and/or the second tearable line of separationincludes a non-linear end portion, such as an arcuate end portion.

The invention still further comprehends a method for using a labelassembly having a face sheet adhered to a back sheet and including aplurality of labels disposed in a label column. The method includes:routing the label assembly through a printer and printing on a firstportion of the label assembly; separating the back sheet along a firsttearable line of separation which extends at least partially below thelabel column; separating the face sheet along a second tearable line ofseparation that is offset with respect to the first tearable line ofseparation and that extends between a label assembly edge and the labelcolumn; tearing a first portion of at least one of the first and secondtearable lines of separation at an angle away from an adjacent portionof an other of the first and second tearable lines of separation;tearing a second portion of the at least one of the first and secondtearable lines of separation to expose an edge portion of each of theplurality of labels disposed in the label column; and removing at leastone of the plurality of labels from the face sheet by pulling from theexposed edge portion.

Other objects and advantages will be apparent to those skilled in theart from the following detailed description taken in conjunction withthe appended claims and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a label assembly according to one embodiment ofthe invention.

FIG. 2 is a plan view of an opposite side of the label assembly of FIG.1.

FIG. 3 is a plan view of the label assembly of FIG. 1 after separationof a first label column portion.

FIG. 4 is a plan view of a label assembly according to anotherembodiment of the invention.

FIG. 5 is an enlarged plan view of a portion of a label assembly,according to another embodiment of the invention.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

Each of U.S. Pat. Nos. 6,837,957 and 6,860,050 and the entire disclosureof each is incorporated into this specification by reference to U.S.Pat. Nos. 6,837,957 and 6,860,050.

FIG. 1 illustrates a label assembly 20 (not necessarily shown to scale),according to one embodiment of the invention. Label assembly 20 isdesirably formed of a face sheet 22 and a back sheet (not shown in FIG.1). The back sheet is desirably about the same size as the face sheet22, but may be differently sized, such as slightly larger or smallerthan the face sheet 22. The surface of the face sheet 22 that isdisposed toward a back sheet 26 includes a layer of an adhesivematerial. The adhesive layer can include any adhesive material known andavailable to those skilled in the art for forming pressure sensitive, orself-adhesive labels. The back sheet 26 is desirably formed of amaterial to which the adhesive coating adheres less than orsignificantly less than to the face sheet 22, such as is known forforming pressure sensitive, or self-adhesive, labels. The adhesivecoating covered by the back sheet 26 is applied to the face sheet 22 inany suitable manner known to those skilled in the art.

The sheet assembly 20 is of any suitable shape, and generally anysuitable size that can be accepted by and fed through a printer, such asa laser printer or an ink jet printer. Common sizes of paper generallyfed through printers are 8.5 inches by 5.5 inches, 8.5 inches by 11inches, 8.263 inches by 11.688 inches (A4 size), and 8.5 inches by 14inches. The face sheet 22 is preferably, but not necessarily,constructed of any suitable paper, paper composite, non-metal and/ormetal material that can be used as a label. Other suitable materials forconstructing the face sheet 22 include, for example, fabric, plastic,and/or metal foils.

The face sheet 22 desirably has a printable surface on a side oppositethe adhesive coating. In some embodiments of the invention, the backsheet 26 has a printable surface, such as on a side opposite theadhesive coating. The phrase “printable surface” relates to a surface ofany type of matter upon which a person or machine can draw, print,color, paint, photocopy, write, emboss, or make any other type of markand/or graphic. Laser printers, ink jet printers, impact printers,thermal transfer printers, direct thermal printers, typewriters, or anyother suitable graphic printing devices are preferred but not necessaryfor use with printable surfaces according to the invention.

The face sheet 22 and the printable surface can be any of a variety offace materials used to make pressure sensitive labels, or self-adhesivelabels. Such face materials may include, but are not limited to:smudgeproof stock, litho stock, cast coated stock, tag stock,fluorescent stock, foils, computer printable polyester, vinyl, satincloth, Tyvek™ material, flexible plastic, book papers, photo qualitypapers and/or photo quality film. Furthermore, various portions of theface materials can be different colors, thereby resulting in differentcolored parts.

As shown in FIG. 1, label assembly 20 can be separated along separationlines 30 to divide label assembly 20 into portions 80, 82, and 84, suchas shown in FIG. 3. As also shown in FIGS. 1 and 4, three separationlines 30 are used to divide label assembly 20, but the label assembly 20will be described below with reference to only one of the separationlines 30. It is apparent that any other suitable number of separationlines 30 can be used to divide label assembly 20 into any suitablenumber of equal or unequal portions. The separation line 30 can beformed by a first tearable line of separation 36 extending across theback sheet 26 and one or more second tearable line of separation 38extending across the face sheet 22. The first and second tearable linesof separation 36 and 38 are offset from each other, for example by lessthan about 1 cm.

As used throughout this specification and in the claims, the phrase“tearable line,” the phrase “line of separation,” and/or the phrase“tearable line of separation” is intended to relate to a line ofweakening of the structure of the face sheet 22 and/or the back sheet26. The line of weakening has a weakened structural area along which theface sheet 22 and/or the back sheet 26 can be separated. Each tearableline or line of weakening, according to the invention, comprises atleast one of a die cut line, a kiss cut line which is a die cut linethat does not extend completely through a layer or a sheet, a laser diecut line, a score cut line, a perforation line which is also known as aline of cuts and ties, a microperforation line, a chemically etchedline, a liquid etched line and/or a gas etched line. Tearable line 36and/or tearable line 38 of the invention may comprise any other suitableseparation line or line of weakening known to those skilled in the artof label assemblies.

The face sheet 22 in FIG. 1 and FIG. 4 includes three label columns 40,each including a plurality of labels 42. The labels 42 are shown asrectangular labels, but can be of any of various shapes such as squareor circular. Also, the shape, dimensions and/or configuration of thelabel columns 40 can vary depending on need and the shape of the labels.For example, the label columns can run vertically as shown, horizontallyand/or diagonally. The number of labels per label column or area dependson the size and shape of the labels.

A matrix 44 can border each of the label columns 40. Each label 42 canabut a portion of the matrix 44 and can be separated from the matrix 44and an adjacent label 42 by a tearable line of separation 46. The firsttearable line of separation 36 formed in the back sheet 26 runs orextends below the labels 42 within the label column 40. In oneembodiment, such as shown in FIG. 3, the second tearable line ofseparation 38 includes a portion that is disposed along, and forms inpart, the labels 42, and extends in a direction generally parallel to aportion of the first tearable line of separation 36.

As used throughout this specification and in the claims, the term“first” and the term “second” and/or other similar terms are intended tobe interchangeable with each other in situations where role reversals ofelements and/or method or process steps are possible.

In some embodiments of the invention, such as shown in FIGS. 1-3, thefirst tearable line of separation 36 includes an angled portion 50 thatextends at an angle to, and toward, the second tearable line ofseparation 38. In other embodiments of the invention, such as shown inFIGS. 4 and 5, the first tearable line of separation 36 includes anon-linear section 51 positioned near edge 58 and/or near edge 60 of thelabel assembly 20. The angled portion 50 and/or the non-linear section51 desirably helps hold the sheet portions together during printing. Atan opposite end of the separation line 30 from the angled portion 50 orthe non-linear section 51, the second tearable line of separation 38includes an angled portion 52 or non-linear section 53 that extends atan angle or arcuately to, and toward, the first tearable line ofseparation 36. The angled portions 50 and 52 or the non-linear sections51 and 53 extend in the matrix 44 or the back sheet 26, respectivelybetween the label column 40 and an edge 58 and an edge 60, respectively,of the label assembly 20. As will be appreciated by those skilled in theart following the teachings herein provided, various and alternativeconfigurations are available for the separation line 30 of theinvention. For example, the two angled portions 50 and 52 or the twonon-linear sections 51 and 53 could both be in the face sheet 22 or theback sheet 26, or only one end of the separation line can include anangled portion or a non-linear section. Also, various angles areavailable for the angled end portions or the non-linear sections of theinvention.

In one particularly preferred embodiment of the invention, referring toFIG. 1, the first tearable line of separation 36 is formed of aperforated line of weakness having a plurality of cuts and ties and thesecond tearable line of separation 38 is formed by a die cut or a kisscut through the face sheet 22. Desirably, the portion of the firsttearable line of separation 36 along the label column 40 includes thecuts and ties, and the angled portion 50 or the non-linear section 51 isformed of only a cut, e.g., a die cut, with no tie within the angledportion 50 or the non-linear section 51. In other embodiments of theinvention, the first tearable line of separation 36 is formed of only adie cut and/or a kiss cut. In some embodiments of the invention, theangled portions 50 and 52 or the non-linear sections 51 and 53 stopshort of the respective edge 58 and/or 60 of the label assembly 20,leaving a breakable material bridge, similar to a tie, at the edge 58and/or 60 in order to provide additional strength and support duringrunning through a printer. In some embodiments, at the edges 58 and 60of the label assembly 20, the first tearable line of separation 36 isseparated from the second tearable line of separation 38 by a distanceof about 0.04 inch to about 0.08 inch, but can be any other suitabledistance.

The first line of separation 36 can include at least a portion runninggenerally parallel to the longitudinal direction of the label column 40,and disposed about 0.4 to about 1.0 centimeters, and desirably about 0.6centimeters, from one longitudinal edge of the label column 40. Theexact distance is not critical, but desirably the first tearable line ofseparation 36 is offset from that edge of the label column 40 far enoughso that when the strip 70 is removed, the labels 42, as shown in FIG. 2,can be easily grasped and removed by the user. At the same time, thefirst line of separation 36 is close enough to a corresponding edge ofthe label column 40 such that when the strip 70 is removed, a narrowenough edge portion 72 of the labels 42 with the adhesive 28 is exposedso that when the label assembly 20 is placed onto a surface, the exposededge of the unremoved labels 42 do not easily and inadvertently stick tothe surface.

FIGS. 2 and 3 illustrate an operation of the separation lines 30 of thelabel assembly 20. FIG. 2 shows the label assembly 20 from the back,showing the back sheet 26. In FIG. 2, the user has grasped one corner oflabel assembly 20 at approximately position 74 as shown in FIG. 1 withone thumb and forefinger, and with the other thumb and forefingergrasped the narrow strip 70 of release liner and matrix so as to focusthe shear forces along the separation line 30, and has began tearingstrip 70 away from the rest of the assembly 20. Alternatively, forexample, one portion of the label assembly 20 can be held against asurface while another portion is lifted away from the surface toseparate the label assembly 20. As shown in FIGS. 1 and 3, the frontsheet 22 can include printed arrows and instructions and/or othergraphics for indicating where to place the fingers during tearing.

The strip 70 tears away as the back sheet 26 is separated along thefirst tearable line of separation 36 and the face sheet 22 separatesalong the second tearable line of separation 38. After the strip 70 iscompletely removed by the user, the previously adjacent label column 40is left or remains with the labels 42 mostly attached to the back sheet26 but having a relatively narrow edge portion 72 of the labels 42 withthe underlying back sheet portion removed. The user can then easily peeloff the individual labels 42 by hand, one-by-one or otherwise asdesired, without having to bend and manipulate the label assembly 20each time the user wishes to remove the next label 42.

FIG. 3 shows the label assembly 20 having a full label column 40 removedtherefrom. As discussed above, the label assembly 20 includes threevertical separation lines 30, with one separation line 30 associatedwith each label column 40. The separation lines 30 divide the labelassembly 20 into three individual label portions 80, 82, and 84, whichmay be individually separated from each other. In FIG. 3, the left handportion 80 has been separated from the still combined or assembledcenter portion 82 and the right hand portion 84. The labels within theleft hand portion 80 are now ready to be easily peeled one by one fromthe back sheet 26 and applied to envelopes or other substrates orsurfaces. Portions 82 and 84 do not have any portions of the labels 42with their adhesive sides exposed. Thus, the portions 82 and 84 can behandled and/or stored for later use without any degradation of theadhesive on the backs of those labels. Remaining portions 82 and 84could even be fed through a printer for later printing. For example, ifonly ten or fewer labels are needed to be printed and used, the usercould run label assembly 20 through a printer and print only on labelswithin the label column in the portion 80. The user would then separatethe portion 80 and use the labels within that portion. Remainingcombined portions 82 and 84 could be stored for later use. Whenadditional labels are ready to be printed, the label assembly 20 couldbe fed through the printer.

FIG. 4 shows another embodiment of the label assembly 20, according tothe invention. As shown in FIG. 4, the second tearable line ofseparation 38 includes or comprises the non-linear section 51 positionednear the edge 60 of the label assembly 20. Also as shown in FIG. 4 bythe dashed lines, the first tearable line of separation 36 includes orcomprises the non-linear section 51 positioned near the edge 58 of thelabel assembly 20. As shown in FIG. 4, the edge 58 is opposite the edge60 on the label assembly 20. However, any other suitable relationshipcan exist between the edge 58 and the edge 60.

In some embodiments of the invention, the non-linear section 51 and/orthe non-linear section 53 each has an arcuate shape. In some embodimentsof the invention, the arcuate shape can have a radius of curvature, forexample in a range from about 0.01 feet to about 5.0 feet, or any othersuitable distance or measurement.

As shown in FIG. 4, the non-linear section 51 arcs in a direction towardthe edge 58. In some embodiments of the invention, the non-linearsection 53 arcs in a direction toward the edge 60. As shown in FIG. 4, afirst direction that the non-linear section 51 arcs is generallyopposite a second direction that the non-linear section 53 arcs. In someembodiments of the invention, the non-linear section 51 has a shapesimilar to the non-linear section 53.

As shown in FIG. 4, the edge 60 is at or near a top of the labelassembly 20, and the edge 58 is at or near the bottom of the labelassembly 20.

As shown in FIG. 4, the first tearable line of separation 36 does notintersect with or avoids intersection with the second tearable line ofseparation 38.

As shown in FIG. 5, the first tearable line of separation 36 intersectsthe edge 58 of the label assembly 20 at a distance 55 from anintersection of the second tearable line 38 and the edge 58. Thedistance 55 can be used to better separate the portions 80, 82 and 84from each other. The arcuate or curved shape of non-linear section 51and/or non-linear section 53 can be used to reduce the forces necessaryfor separating the portions 80, 82 and/or 84 with respect to each other.

Thus, the invention provides an improved label assembly structure forpromoting easy removal of labels from the label assembly.

The invention illustratively disclosed herein suitably may be practicedin the absence of any element, part, step, component, or ingredientwhich is not specifically disclosed herein.

While in the foregoing detailed description this invention has beendescribed in relation to certain preferred embodiments thereof, and manydetails have been set forth for purposes of illustration, it will beapparent to those skilled in the art that the invention is susceptibleto additional embodiments and that certain of the details describedherein can be varied considerably without departing from the basicprinciples of the invention.

1. In a label assembly having a face sheet, a back sheet, an adhesivepositioned between at least a portion of a coextensive area of said facesheet and said back sheet, at least one separation line dividing thelabel assembly into at least two portions, each said separation line atleast partially formed by a first tearable line of separation extendingacross said back sheet and a second tearable line of separationextending across said face sheet, and each said first tearable line ofseparation offset with respect to said second tearable line ofseparation, the label assembly comprising: a first end portion of thefirst tearable line of separation having a first non-linear sectionpositioned near a first edge of the label assembly, and a second endportion of the second tearable line of separation having a secondnon-linear section positioned near a second edge of the label assemblywhich is at a distance from the first edge.
 2. In the label assemblyaccording to claim 1, wherein the first non-linear section and/or thesecond non-linear section has an arcuate shape.
 3. In the label assemblyaccording to claim 2, wherein at least a portion of the arcuate shapehas a radius of curvature in a range from about 0.01 feet to about 5.0feet.
 4. In the label assembly according to claim 2, wherein the firstnon-linear section arcs in a first direction toward the first edge, thesecond non-linear section arcs in a second direction toward the secondedge, and the first direction is generally opposite the seconddirection.
 5. In the label assembly according to claim 1, wherein thefirst non-linear section has a shape similar to the second non-linearsection.
 6. In the label assembly according to claim 1, wherein thefirst edge is at a top of the label assembly and the second edge is at abottom of the label assembly.
 7. In the label assembly according toclaim 1, wherein the first tearable line of separation and the secondtearable line of separation avoid intersection with each other.
 8. Inthe label assembly according to claim 1, wherein the first tearable lineof separation intersects the first edge at a distance from anintersection of the second tearable line of separation and the firstedge.
 9. In the label assembly according to claim 1, wherein the secondtearable line of separation intersects the second edge at a distancefrom an intersection of the first tearable line of separation and thesecond edge.
 10. In the label assembly according to claim 1, wherein thefirst tearable line of separation and/or the second tearable line ofseparation comprises a die cut line, a laser die cut line, a score cutline, a kiss cut line, a perforation line, a microperforation line, achemically etched line, a liquid etched line, or a gas etched line. 11.In the label assembly according to claim 1, wherein the first tearableline of separation comprises a plurality of cuts and ties and the secondtearable line of separation comprises a die cut or a kiss cut.
 12. Inthe label assembly according to claim 1, further comprising a labelcolumn of a plurality of labels positioned within the face sheet,wherein the separation line is adjacent the label column.
 13. In thelabel assembly according to claim 1, wherein the adhesive forms a layersurrounding a first area between the face sheet and the back sheet, andthe at least one first tearable line of separation intersects the firstarea.
 14. The label assembly according to claim 1, wherein the at leasttwo portions are separable from each other.
 15. A label assemblycomprising: a face sheet, a back sheet, a layer of an adhesivepositioned between said face sheet and said back sheet, said adhesiveadhering to said face sheet more than to said back sheet; and aseparation line dividing the label assembly into at least two portions,the separation line formed by at least one first tearable line ofseparation extending across said back sheet and a second tearable lineof separation extending across said face sheet, and each said firsttearable line of separation being offset with respect to said secondtearable line of separation, and a non-linear end portion of the firsttearable line of separation extending to an edge of the label assembly.16. The label assembly according to claim 15, wherein the non-linear endportion has an arcuate shape.
 17. The label assembly according to claim16, wherein at least a portion of the arcuate shape has a radius ofcurvature in a range from about 0.01 feet to about 5.0 feet.
 18. Thelabel assembly according to claim 16, wherein in a direction toward anedge of the label assembly, the non-linear end portion arcs toward thesecond tearable line of separation.
 19. A label assembly comprising: aface sheet, a back sheet, an adhesive between said face sheet and saidback sheet, said adhesive adhering to said face sheet more than to saidback sheet, a first tearable line of separation extending across saidback sheet and a second tearable line of separation extending acrosssaid face sheet, said first tearable line of separation spaced apartfrom said second tearable line of separation, a first arcuate endportion of the first tearable line of separation extending to a firstedge of the label assembly, and a second arcuate end portion of thesecond tearable line extending to a second edge which is different fromsaid first edge of the label assembly.
 20. In the label assemblyaccording to claim 19, wherein the first tearable line of separationintersects the first edge at a distance from an intersection of thesecond tearable line of separation and the first edge.